Manual de Operador Onan 10HDCAC

7/29/2019 Manual de Operador Onan 10HDCAC

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HDCAA, HDCAB, HDCAC, HDCAD

Printed in U.S.A. 981-0526D02-04

Redistribution or publication of this docume

by any means, is strictly prohibite


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California

Proposition 65 WarningDiesel engine exhaust and some of its constituents are knownto the State of California to cause cancer, birth defects, and

other reproductive harm.

diesel warnings




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Page 1 of 1

Supplement:981-1049

Date: 09/04

Insert with-

Manual Number (Date): 981-0173 (08/04) 981-0174 (08/04) 981-0540 (08/04)

981-0170 (11/03) 981-0171 (11/03) 981-0526D (02/04)

981-0166B (06/03) 981-0167B (06/03) 981-0535 (10/02)

981-0161 (08/89) 981-0522B (07/99)

Purpose:These instructions supplement the instructions for filling the engine cooling system found in thePeriodic Maintenancesections of the Operators and Service Manuals listed above.

WARNING To prevent severe burns from hot coolant under pressure, carefully observe all of theSafety Precautions and Instructions in the Manual for handling and filling coolant.

Instructions:Use a funnel when filling the cooling system through the fill opening (Figure 1) to preventcoolant from entering the vent hose and blocking the escape of air as the system fills. The system will seem fullwhen it actually is notif the air cannot escape through the vent hose. If the vent hose does get blocked, pinch

the overflow hose and blow the vent hose clear.CAUTION Coolant trapped in the vent hose will prevent the system from filling to its capacity, which

can lead to serious engine damage.

PRESSURE CAPAND SYSTEM FILL

OPENING

FIGURE 1. TYPICAL COOLANT FILL OPENING WITH CONNECTED FILL, OVERFLOW AND VENT HOSES

Redistribution or publication of this document,

by any means, is strictly prohibited.


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Table of Contents

SECTION PAGE

SAFETY PRECAUTIONS iii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. INTRODUCTION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About this Manual 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Recommendations 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil Recommendations 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting Batteries 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. OPERATION 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Panel (Beginning Spec C) 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Panel (Prior to Spec C) 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Control 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Priming the Fuel System 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Starting 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Stopping 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Starting and Stopping 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. PERIODIC MAINTENANCE 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Inspections 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Engine Oil Level 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Engine Oil and Oil Filter 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintaining the Battery and Battery Connections 3-5. . . . . . . . . . . . . . . . . . . . . . . . . .Replacing the Air Filter Element 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the Spark Arrestor 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Fuel Filter 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Coolant 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. PREPARATIONS FOR SERVICE 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Tools 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing / Installing Genset 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test Stand 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disassembling / Reassembling Housing 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. FUEL SYSTEM 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Injection System 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Filter 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Pump 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. AIR INTAKE SYSTEM 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. EXHAUST SYSTEM 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .




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SECTION PAGE

8. ENGINE COOLING SYSTEM 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Thermostat and Pump 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fan (Blower) 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fan Belt 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9. ENGINE AND ACCESSORIES 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Sensors 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Charging Alternator 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starter Motor 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Glow Plugs 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Governor Actuator 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High-Idle Speed 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10. GENERATOR 10-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Winding Tests 10-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Service 10-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting Voltage 10-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11. CONTROL 11-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Board (Controller) 11-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Local and Remote Control Switches 11-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relays K1, K2, K3 11-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Fuses F1, F2 11-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hour Meter 11-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Line Circuit Breakers CB1, CB2 11-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12. TROUBLESHOOTING 12-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting With Table 12-1 12-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault Code Blinking 12-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Restoring Fault Code Blinking 12-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bypassable Faults 12-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13. SERVICE CHECKLIST 13-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14. SPECIFICATIONS 14-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15. THREAD TORQUES 15-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING SCHEMATIC (BEGINNING SPEC C) A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROL WIRING HARNESS (BEGINNING SPEC C) A-2. . . . . . . . . . . . . . . . . . . . . . . . . .

AC WIRING HARNESS AND CHASSIS GROUNDS A-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING SCHEMATIC (PRIOR TO SPEC C) A-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROL WIRING HARNESS (PRIOR TO SPEC C) A-5. . . . . . . . . . . . . . . . . . . . . . . . . . . .




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Safety Precautions

Thoroughly read the OPERATORS MANUALbefore operating the genset.Safe operation andtop performance can only be obtained when

equipment is operated and maintained proper-ly.

The following symbols in this manual alert you topotential hazards to the operator, service personand equipment.

DANGER alerts you to an immediate hazardthat will result in severe personal injury ordeath.

WARNING alerts you to a hazard or unsafe

practice that can result in severe personal inju-ry or death.

CAUTION alerts you to a hazard or unsafepractice that can result in personal injury orequipment damage.

Electricity, fuel, exhaust, moving parts and batter-ies present hazards which can result in severe per-sonal injury or death.

GENERAL PRECAUTIONS

Keep children away from the genset.

Do not use evaporative starting fluids. Theyare highly explosive.

To prevent accidental or remote startingwhile working on the genset, disconnect thenegative () battery cable at the battery.

Let the engine cool down before removingthe coolant pressure cap or opening thecoolant drain. Hot coolant under pressurecan spray out and cause severe burns.

Keep the genset and its compartment clean.Excess oil and oily rags can catch fire. Dirtand gear stowed in the compartment can re-strict cooling air.

Make sure all fasteners are secure andtorqued properly.

Do not work on the genset when mentally orphysically fatigued or after consuming alco-hol or drugs.

You must be trained and experienced tomake adjustments while the genset is run-ninghot, moving or electrically live partscan cause severe personal injury or death.

Used engine oil has been identified by someU. S. state and federal agencies as causingcancer or reproductive toxicity. Do not ingest,inhale, or contact used oil or its vapors.

Ethylene glycol, used as engine antifreeze, istoxic to humans and animals. Clean up spillsand dispose of used engine coolant in accor-

dance with local environmental regulations.

Keep multi-class ABC fire extinguishershandy. Class A fires involve ordinary com-bustible materials such as wood and cloth;Class B fires, combustible and flammableliquid fuels and gaseous fuels; Class C fires,live electrical equipment. (ref. NFPA No. 10)

Genset installation and operation must com-ply with all applicable local, state and federalcodes and regulations.

GENERATOR VOLTAGE IS DEADLY Disable the automatic genset starting feature

of an inverter-charger or other automaticstarting device before servicing the genset.

Generator electrical output connections mustbe made by a trained and experienced elec-trician in accordance with applicable codes.

The genset must not be connected to thepublic utility or any other source of electricalpower. Back-feed could lead to electrocutionof utility personnel and damage to equip-

ment. An approved switching device must beused to prevent interconnections.

Use caution when working on live electricalequipment. Remove jewelry, make sureclothing and shoes are dry, stand on a drywooden platform or rubber insulating matand use tools with insulated handles.




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ENGINE EXHAUST IS DEADLY

Learn the symptoms of carbon monoxidepoisoning in this manual.

Never sleep in the vehicle while the genset isrunning unless the vehicle is equipped with aworking carbon monoxide detector.

Make sure there is ample fresh air when op-erating the genset in a confined area.

Disable the automatic genset starting featureof an inverter-charger or other automaticstarting device before storing the vehicle orparking it in a garage or other confinedspace.

The exhaust system must be installed in ac-cordance with the genset Installation Manual.

Engine cooling air must not be used for heat-ing working or living spaces or compart-ments.

DIESEL FUEL IS COMBUSTIBLE

Do not smoke or turn electrical switches ONor OFF where fuel fumes are present or inareas sharing ventilation with fuel tanks orequipment. Keep flames, sparks, pilot lights,arc-producing equipment and all othersources of ignition well away.

Fuel lines must be secured, free of leaks andseparated or shielded from electrical wiring.

BATTERY GAS IS EXPLOSIVE

Wear safety glasses.

Do not smoke.

To reduce arcing when disconnecting or re-connecting battery cables, always disconnectthe negative () battery cable first and recon-

nect it last.

MOVING PARTS CAN CAUSE SEVEREPERSONAL INJURY OR DEATH

Disable the automatic genset starting featureof an inverter-charger or other automaticstarting device before servicing the genset.

Do not wear loose clothing or jewelry nearmoving parts such as PTO shafts, fans, beltsand pulleys.

Keep hands away from moving parts.

Keep guards in place over fans, belts, pul-leys, and other moving parts.

FLAMMABLE VAPOR CAN CAUSE ADIESEL ENGINE TO OVERSPEED

Flammable vapor can cause a diesel engine tooverspeed and become difficult to stop, resulting inpossible fire, explosion, severe personal injury anddeath. Do not operate a diesel-powered gensetwhere a flammable vapor environment can becreated by fuel spill, leak, etc. The owners and

operators of the genset are solely responsible foroperating the genset safely.

Mobile-8




9/821-1

1. Introduction

ABOUT THIS MANUAL

This is the service manual for the generator sets(gensets) listed on the front cover. Read and care-fully observe all of the instructions and precautionsin this manual.

WARNING This genset is not a life support sys-tem. It can stop without warning. Children, per-sons with physical or mental limitations, andpets could suffer personal injury or death. A per-sonal attendant, redundant power or an alarmsystem must be used if genset operation is criti-cal.

WARNING Improper service or replacement ofparts can lead to severe personal injury or deathand to damage to equipment and property. Ser-vice personnel must be qualified to performelectrical and mechanical service.

WARNING Unauthorized modifications or re-placement of fuel, exhaust, air intake or speedcontrol system components that affect engine

emissions are prohibited by law in the State ofCalifornia.

See the Installation Manual for important recom-mendations concerning the installation and for a listof the installation codes and standards for safetywhich may be applicable.

See the Parts Manual for part identification numbersand required quantities. Genuine Onan replace-ment parts are recommended for best results.

When contacting Onan for parts and product infor-mation, be ready to provide the model and serialnumbers on the genset nameplate. Figure 1-1 illus-trates the nameplate and its location. The numbersin the gray boxes are typical model and serial num-bers. Every character in these numbers is signifi-cant. (The last character of the model number is thespecification letter, which is important for obtainingthe right parts.)

[The engine family designation, engine displacement, state-ment of compliance with applicable EPA and / or Californiaemissions regulations appear in this block on the actual name-plate on the genset.]

FIGURE 1-1. TYPICAL NAMEPLATE




10/821-2

FUEL RECOMMENDATIONS

WARNING Diesel fuel is combustible and cancause severe personal injury or death. Do notsmoke near fuel tanks or fuel-burning equip-ment or in areas sharing ventilation with suchequipment. Keep flames, sparks, pilot flames,electrical arcs and switches and all other

sources of ignition well away. Keep a multi-class ABC fire extinguisher handy.

Use clean, fresh No. 2 diesel fuel (ASTM 2-D) whenthe outdoor ambient temperature is above freezing,and No. 1 diesel fuel (ASTM 1-D) when below freez-ing. The fuel should have a Cetane number of atleast 45 for reliable starting.

ENGINE OIL RECOMMENDATIONS

Use API (American Petroleum Institute) perfor-mance Class CH-4 engine oil or better. Also look forthe SAE (Society of Automotive Engineers) viscos-

ity grade. Referring to Figure 1-2, choose the vis-cosity grade appropriate for the ambient tempera-tures expected until the next scheduled oil change.Multi-grade oils such as SAE 15W-40 are recom-mended for year-round use.

STARTING BATTERIES

The genset requires a 12 volt battery to power itscontrol and starting circuits. Reliable genset startingand starter service life depend upon adequate bat-tery system capacity and maintenance. See MAIN-TAINING THE BATTERY AND BATTERY CON-

NECTIONS (p. 3-5) and Section14. Specifications.

FIGURE 1-2. OIL VISCOSITY VS. TEMPERATURE




11/822-1

2. Operation

CONTROL PANEL (BEGINNING SPEC C)

The control panel (Figure 2-1) has the following fea-

tures:

Control Switch This switch is used to start andstop the genset, prime the engine fuel system andrestore the fault code (blinking status light).

Status Light This is an LED (light emitting diode)in the control switch which blinks rapidly during pre-heat and cranking. After the genset starts up, thislight stays on continuously, indicating that the gen-set is running and that the starter has disconnected.If the genset shuts down, this light blinks a numeri-cal code to indicate the nature of the fault shutdown(see Section12. Troubleshooting).

(Rapid blinking before cranking starts indicates thatthe glow plugs are preheating the combustionchambers. The controller automatically varies the

time based on engine temperature.)

Line Circuit Breaker(s) The line circuit breakersprotect the AC power leads connected to the gen-set.

Coolant Recovery Tank Fill Cap The recoverytank provides for coolant expansion. Replenish thenormal loss of coolant by filling here.

Hour Meter The hour meter records the total run-ning time of the genset. It cannot be reset.

COOLANT RECOVERYTANK FLUID LEVEL

LINE CIRCUIT

BREAKER(S)

HOUR METERCONTROL SWITCH

&STATUS LIGHT

COOLANT RECOVERYTANK FILL CAP

FIGURE 2-1. CONTROL PANEL (BEGINNING SPEC C)




12/822-2

CONTROL PANEL (PRIOR TO SPEC C)

The control panel (Figure 2-2) has the following fea-tures:

Control Switch This switch is used to start andstop the genset, prime the engine fuel system andrestore the blinking fault code.

Status Light This is an LED (light emitting diode)in the control switch which blinks rapidly during pre-heat and cranking. After the genset starts up, thislight stays on continuously, indicating that the gen-set is running and that the starter has disconnected.If the genset shuts down, this light blinks a numeri-cal code to indicate the nature of the fault shutdown(see Section12. Troubleshooting).

(Rapid blinking before cranking starts indicates thatthe glow plugs are preheating the combustionchambers. The controller automatically varies the

time based on engine temperature.)

Line Circuit Breaker(s) The line circuit break-er(s) protect the AC power leads connected to thegenset.

Coolant Recovery Tank Fill Cap The recoverytank provides for coolant expansion. Replenish thenormal loss of coolant by filling here.

Coolant Pressure Cap The coolant pressure capis accessible by removing the access plate on thecontrol console. Fill coolant here when refilling thesystem.

Fuses F1 and F2 These fuses are accessible byremoving the access plate on the control panel.

They protect the control circuits of the genset.

Hour Meter The hour meter records the total run-ning time of the genset. It cannot be reset.

REMOTE CONTROL

The vehicle is probably equipped with a remote con-trol panel having a Control Switch, StatusLightand Hour Meter. For models prior to Spec C thepanel may also have the following engine gauges:

Oil Pressure Gauge The oil pressure gauge indi-cates engine oil pressure.

Water Temperature Gauge The water tempera-ture gauge indicates engine coolant temperature.

Voltmeter The voltmeter indicates DC systemvoltage.

COOLANT RECOVERYTANK FLUID LEVEL

LINE CIRCUITBREAKER(S)

ACCESS TO CONTROL FUSESF1 & F2, ENGINE COOLANT

FILL & PRESSURE CAP

CONTROL SWITCH&STATUS LIGHT HOUR METER

ENGINE COOLANTRECOVERY TANK FILL CAP

FIGURE 2-2. CONTROL PANEL (PRIOR TO SPEC C)




13/822-3

WARNING EXHAUST GAS is deadly. All en-gine exhaust contains carbon monoxide; anodorless, colorless, poisonous gas that cancause unconsciousness and death. Symptomsof carbon monoxide poisoning include:

Dizziness Headache Nausea Weakness and Sleepiness

Vomiting Inability to Think Coherently

IF YOU EXPERIENCE ANY OF THESE SYMP-TOMS, GET INTO FRESH AIR IMMEDIATELY. Ifsymptoms persist, seek medical attention. Shutdown the genset and do not operate it until it hasbeen inspected and repaired.

Never sleep in the vehicle while the genset isrunning unless the vehicle has a working car-bon monoxide detector. The exhaust systemmust be installed in accordance with the gensetInstallation Manual. Make sure there is ample

fresh air when operating the genset in a con-fined area.

PRIMING THE FUEL SYSTEM

The fuel system should be primed after replacingthe fuel filter or running the genset out of fuel. Toprime the fuel system, hold the control switch downin its Stop position for at least 1 minute.

MANUAL STARTING

The genset can be started and stopped from the

genset control panel or from a remote control panelinside the vehicle.

1. Perform the PRE-START CHECKS, prime thefuel system if necessary, and turn off the airconditioners and other large electrical loads.

2. Push the control switch to its Start position andhold it there while the status light blinks rapidlyindicating preheat and crank. Let go when thelight comes on continuously. (Depending onhow cold it is, preheat can take up to 15 sec-onds, extending the time that the light blinks.)

CAUTION Excessive cranking can over-heat and damage the starter motor. Do notcrank for more than 30 seconds at a time.Wait at least 2 minutes before trying again.

3. See Section12. Troubleshootingif the gensetdoes not start after several tries.

4. Let the genset warm up a few minutes until it isrunning smoothly before connecting the ve-hicle electrical loads (appliances).

5. Monitor the engine gauges if the remote panelis so equipped (prior to Spec C). Normal read-ings during operation are as follows:

Oil Pressure:Approximate center of scale

Temperature:160-220 F (71-104 C)

DC Voltage:14-15 volts.

6. Check for fuel and exhaust leaks. Stop the gen-set immediately if there is a fuel, coolant or ex-haust leak and have it repaired before continu-ing operation.

MANUAL STOPPING

Run the genset under no load for a few minutes toallow the engine to cool down and then push thecontrol switch briefly to its Stop position.

AUTOMATIC STARTING AND STOPPING

The vehicle may be equipped with an inverter-char-ger or other automatic genset starting device. Al-ways follow the device manufacturers instructionsand safety precautions to enable automatic gensetstarting.

WARNING EXHAUST GAS is deadly. MOV-ING PARTS and ELECTRICITY can cause severepersonal injury or death. To reduce exposure tothese hazards, always disable automatic gensetstarting before:

S Sleeping in vehicle, unless vehicle has aworking CARBON MONOXIDE detector

S Parking vehicle in garage or confined space

S Parking vehicle for storage

S Servicing genset

S Servicing batteries

S Servicing electrical appliances

S Fueling vehicle




14/822-4

THIS PAGE IS INTENDED TO BE BLANK




15/823-1

3. Periodic Maintenance

Periodic maintenance is essential for top perfor-mance and long genset life. Use Table 3-1 as aguide for normal periodic maintenance. In hot and

dusty environments some maintenance proceduresshould be performed more frequently, as indicatedby the footnotes in the table.

Maintenance, replacement or repair of emissioncontrol devices and systems may be performed byany engine repair establishment or individual. How-

ever, warranty work must be completed by an au-thorized Onan dealer.

TABLE 3-1. PERIODIC MAINTENANCE SCHEDULE

MAINTENANCE FREQUENCY

MAINTENANCE OPERATION EveryDay

AfterFirst 50Hours

EveryMonth

Every150

Hours

Every250

Hours

Every500

Hours

Every1000Hours

Page

General Inspections 3-2

Check Engine Oil Level 3-3

Check Engine Coolant Level 3-8

Clean and Check Battery 2 3-5

Clean Spark Arrestor 3 3-6

Change Engine Oil and Oil Filter 1,2,3 3-4

Check V-Belt Tension 7 8-1

Replace Engine Air Filter 1,3 3-5

Replace Fuel Filter 3 3-7

Check Coolant Anti-Freeze Protection 3 3-8

Flush Coolant System 4 3-8

Replace Coolant Pressure Cap 4 3-8

Replace Engine V-belt 5,6 8-1

Replace Coolant Hoses 5,6 8-1

Replace Coolant Thermostat 5,6 8-1

Adjust Engine Valve Lash 5,6 9-1

Service Fuel Injectors 5,6 9-1

1 Perform more often when operating in dusty conditions.2 Perform more often when operating in hot weather.3 Perform at least once a year.4 Perform at least once every two years.5 Perform at least once every five years.6 Must be performed by a qualified mechanic (authorized Onan dealer).7 Tighten or replace the belt in accordance with the Service Manual if it can be deflected more than 1/2 in (12 mm) by thumb.




16/823-2

GENERAL INSPECTIONS

Inspect the genset before the first start of the dayand after every eight hours of operation.

Oil Level

Check engine oil level (Figure 3-1).

Engine Coolant System

CAUTION Operating the genset when coolantlevel is low can cause serious engine damage.

Check the engine coolant level and look for coolantleaks around the bottom of the genset and on theground below. Minor leaks that can be replenishedby daily additions of coolant to the recovery tankshould be repaired by a qualified service technicianas soon as possible. Larger leaks are cause for

shutting down the genset until it can be repaired.Exhaust System

WARNING EXHAUST GAS IS DEADLY! Do notoperate the genset if there is an exhaust leak orany danger of exhaust gases entering or beingdrawn into the vehicle.

Look and listen for exhaust system leaks while thegenset is running. Shut down the genset if a leak isfound and have it repaired before operating the gen-set again.

Look for openings or holes between the gensetcompartment and vehicle cab or living space if thegenset engine sounds louder than usual. Have allsuch openings or holes closed off or sealed to pre-vent exhaust gases from entering the vehicle.

Replace dented, bent or severely rusted sections ofthe tailpipe and make sure the tailpipe extends atleast 1 inch (25.4 mm) beyond the perimeter of thevehicle.

WARNING Do not park the vehicle in high grassor brush. Contact with the exhaust system cancause a fire.

Park the vehicle so that the genset exhaust gasescan disperse away from the vehicle. Barriers suchas walls, snow banks, high grass and brush and oth-er vehicles can cause exhaust gases to accumulatein and around the vehicle.

Do not operate power ventilators or exhaust fans

while the vehicle is standing with the genset run-ning. The ventilator or fan can draw exhaust gasesinto the vehicle.

Fuel System

Check for leaks at hose, tube and pipe fittings in thefuel supply system while the genset is running andwhile it is stopped. Check flexible fuel hose sectionsfor cuts, cracks, and abrasions. Make sure the fuelline is not rubbing against other parts. Replace wornor damaged fuel line parts before leaks occur.

WARNING Diesel fuel leaks can lead to fire. Donot operate the genset if operation causes fuelto leak.

Prime the fuel system if the genset ran out of fuel.

Battery Connections

Check the battery terminals for clean, tight connec-tions. Loose or corroded connections have highelectrical resistance which makes starting harder.

See MAINTAINING THE BATTERY AND BATTERYCONNECTIONS (p. 3-5).

Mechanical

Look for mechanical damage and listen for unusualnoises. Check the genset mounting bolts.

To prevent overheating and to reduce fouling withdust and debris, make sure the gensets normalground clearance is not being reduced by slopingground, curbs, logs or other objects. Repark the ve-hicle if necessary and/or remove any objects block-ing the air inlet or air outlet.




17/823-3

CHECKING ENGINE OIL LEVEL

WARNING State and federal agencies have de-termined that contact with used engine oil cancause cancer or reproductive toxicity. Avoidskin contact and breathing of vapors. Use rub-ber gloves and wash exposed skin.

1. Park the vehicle on level ground, shut down thegenset and remove the front access door.

2. Pull out the oil dip stick, wipe it clean, reinsertit and pull it out again to check the oil level (Fig-ure 3-1).

3. Add or drain oil as necessary. See ENGINE OILRECOMMENDATIONS (p. 1-2). Keep the oillevel between the FULL and ADD marks.

CAUTION Too much oil can cause high oilconsumption. Too little oil can cause severeengine damage. Keep the oil level betweenthe FULL and ADD marks.

4. Reinsert the dipstick and secure the oil fill capand front access door.

FIGURE 3-1. CHECKING ENGINE OIL LEVEL




18/823-4

CHANGING ENGINE OIL AND OIL FILTER

WARNING State and federal agencies have de-termined that contact with used engine oil cancause cancer or reproductive toxicity. Avoidskin contact and breathing of vapors. Use rub-ber gloves and wash exposed skin.

Refer to Table 3-1 for scheduled engine oil change.Change oil more often in hot and dusty environ-ments.

1. Place a pan under the oil drain plug (Fig-ure 3-2), run the genset until warm and shut itoff.

2. Remove the front access door and the oil fill cap(Figure 3-1), unscrew the oil drain plug (24 mmhex head) and drain all the oil from the engine.Reinstall the oil drain plug securely.

3. Spin off the oil filter canister (Figure 3-1) andclean the filter mounting surface on the engineblock. Remove the old gasket if it remains.

4. Make sure the gasket is in place on the new fil-ter and apply a thin film of clean oil to the gas-ket. Spin the new filter on until the gasket justtouches the block. Turn it an additional 1/2 to3/4 turn. Do not overtighten.

5. Refill with 6.7 quarts (6.3 liters) of oil, check thelevel (Figure 3-1) and secure the front accessdoor.

6. Dispose of the used oil and oil filter accordingto local environmental regulations.

OIL DRAIN PLUG(24 MM HEX HEAD)

FIGURE 3-2. OIL DRAIN PLUG




19/823-5

MAINTAINING THE BATTERY ANDBATTERY CONNECTIONS

WARNING Arcing at battery terminals or inlight switches or other equipment, and flames orsparks, can ignite battery gas causing severepersonal injuryVentilate battery area beforeworking on or near batteryWear safety

glassesDo not smokeSwitch work light ONor OFF away from batteryStop genset and dis-connect charger before disconnecting batterycablesDisconnect negative () cable first andreconnect last.

Refer to Table 3-1 for scheduled battery mainte-nance, and follow the battery manufacturers in-structions. Have the battery charging system ser-viced if DC system voltage is consistently low orhigh. Always:

1. Keep the battery case and terminals clean and

dry and the terminals tight.2. Remove battery cables with a battery terminalpuller.

3. Make sure which terminal is positive (+) andwhich is negative () before making batteryconnections, always removing the negative ()cable first and reconnecting it last to reducearcing.

REPLACING THE AIR FILTER ELEMENT

Refer to Table 3-1 for scheduled air filter element re-placement. In dusty environments the filter element

should be inspected and changed more frequently.The air filter is accessible through the front accessdoor (Figure 3-3). Loosen the three screws that se-cure the coolant recovery tank to the top housingpanel (removed to show air filter) and move the tankout of the way. To change the air filter element, re-move the end cap, withdraw the element and re-assemble with a new air filter element. Secure theaccess door.

AIR FILTERHOUSING

FIGURE 3-3. AIR FILTER




20/823-6

CLEANING THE SPARK ARRESTOR

Refer to Table 3-1 for scheduled cleaning of thespark arrestor muffler (which meets U.S. ForestService requirements). Cleaning is required formaximum genset performance.

WARNING A hot muffler can cause severeburns. Let the muffler cool down before remov-ing or installing the cleanout plug.

The muffler is mounted inside the genset housing.The spark arrestor cleanout plug is located on theside of the muffler and is accessible through the topaccess opening (Figure 3-4). Clean out the muffleras follows:

1. Remove the top access cover.

2. Remove the cleanout plug from the muffler andsecure the top access cover before running thegenset (11/16 inch hex head or 7/16 inchsquare head plug). With the cover in placethere will be enough air flow to cool the engineproperly and carry the soot out of the compart-

ment.

3. Start the genset and load it nearly to full power.Let the genset run for about five minutes to ex-pel the soot.

4. Stop the genset, allow the muffler to cool down,reinstall the cleanout plug and secure the ac-cess cover.

11/16 INCH HEX HEADOR 7/16 INCH SQUARE

HEAD PLUG

FIGURE 3-4. SPARK ARRESTOR CLEANOUT PLUG




21/823-7

REPLACING THE FUEL FILTER

WARNING Diesel fuel is combustible and cancause severe personal injury or death. Do notsmoke near diesel fuel tanks or equipment.Keep flames, sparks, pilot lights, electricalswitches, arc-producing equipment and all oth-

er sources of ignition well away. Keep a typeABC fire extinguisher in the vehicle.

Close any fuel line shutoff valve before discon-necting the fuel line from the filter.

WARNING To prevent accidental or remotestarting while working on the genset, discon-nect the negative () battery cable at the battery.

See Table 3-1 for scheduled fuel filter replacement.A dirty fuel filter may be the cause of a failure to start.The fuel filter is accessible through the front access

door (Figure 3-5).

CAUTION Wipe dirt off the fuel hose fittings atthe fuel filter before disconnecting the hoses soas to keep dirt out of the fuel system.

Removing the Fuel Filter:Take care to spill as littlefuel as possible when disconnecting the filter from

the fuel line. Close any shut off valve in the fuel line.Wipe dirt off the fuel hose fittings at the filter.

To remove the filter, disconnect the two fittings at thefilter and remove the mounting nut. Apply a wrenchon the filter fitting as well as on the flare nut so as notto stress the fitting. Flare nut wrenches should be

used on the flare nuts so as not to round the cornerson the nuts. Dispose of the fuel filter according to lo-cal regulations.

Installing the Fuel Filter:Rotate the filter half aturn around its mounting stud if the fittings interferewith the bracket. It only fits properly one way.

Connect the fuel fittings before tightening the filtermounting nut. Take care not to crossthread the fuelfittings. Thread them in by hand and tighten one flatpast seating.

Prime the fuel system by holding the control switchdown in its Stop position for at least 1 minute afterreplacing the fuel filter. Priming is necessary to dis-place the air in the new filter and fill it with fuel.

Secure the access door.

FUELINJECTOR

(1 OF 3)

FUELFILTER

HOSE FITTING(TO INJECTOR PUMPS)

FILTER MOUNTINGNUT

FUEL INJECTORPUMP

(1 OF 3)

FUEL LIFTPUMP

TUBING FITTING(FROM LIFT PUMP)

FIGURE 3-5. FUEL FILTER




22/823-8

CHANGING COOLANT

Refer to Table 3-1 for scheduled maintenance. Theengine cooling system is filled with a 50/50 mixtureof ethylene glycol anti-freeze and water when thegenset leaves the factory, which is suitable for tem-

peratures down to -34 F (-37 C).

Recommended Coolant Mixture

Use the best quality ethylene glycol antifreeze solu-tion available. It should be fully formulated with rustinhibitors and coolant stabilizers. Use fresh waterthat is low in minerals and corrosive chemicals. Dis-tilled water is best. The cooling system has a6.1 quart (5.8 L) capacity.

Pressure Cap

Replace the pressure cap (Figure 3-6) every two

years (seals deteriorate and leak). Proper coolingsystem pressure (14 psi) is essential for optimal en-gine cooling and minimal coolant loss.

Draining and Cleaning Cooling System

WARNING Hot coolant spray can cause severeburns. Let the engine cool before releasing thepressure cap or removing the drain cap.

Let the engine cool before removing the pressurecap. Relieve any remaining pressure by turning the

pressure cap slowly, without pushing down. Whenthe pressure has been relieved, push down on thecap, turn it the rest of the way and withdraw it. Then

remove the coolant drain cap (Figure 3-6) and drainthe coolant into a suitable container.

WARNING Ethylene glycol antifreeze is con-sidered toxic. Dispose of it according to localregulations for hazardous substances.

Flush and clean the cooling system before refilling.

Radiator cleaning chemicals are available at localauto parts stores. Follow the instructions for clean-ing and flushing that come with the cleaning solu-tion.

Refilling Cooling System

Wet the O-ring in the coolant drain cap with coolantand thread the cap on just snug with a wrench. Toavoid damaging the O-ring, do not torque to morethan 5 lb-ft (6.8 N-m). Replace the O-ring if snug-ging the cap a little tighter does not stop leakage.

Fill the system with coolant through the fill opening.Pull the hose connected to the pressure cap assem-bly out as far as it will go. When the coolant levelreaches the fill opening, start and operate the gen-set for a few minutes and shut it down. Add morecoolant if necessary and secure the pressure cap.

Fill the recovery tank with coolant mixture to theCOLD mark.

Coolant Level Check

Check coolant level in the recovery tank (Fig-ure 3-6) before the first startup of each day and fill tothe COLD mark if necessary.




23/823-9

RECOVERY TANK

FLUID LEVEL

RECOVERY TANKFILL CAP (BLUE)

PRESSURE CAPAND SYSTEMFILL OPENING

COOLANT DRAIN CAP(19 MM HEX)

TORQUE TO 5 LBFT(6.8 NM) MAX

PRESSURE CAPAND SYSTEMFILL OPENING

BEGINNING SPEC C

PRIOR TO SPEC C

RECOVERY TANKFLUID LEVEL

COOLANT RECOVERYTANK FILL CAP (BLUE)

COOLANT DRAIN CAP(19 MM HEX)

TORQUE TO 5 LBFT(6.8 NM) MAX

FIGURE 3-6. ENGINE COOLING SYSTEM FILL AND DRAIN CAPS




24/823-10





25/824-1

4. Preparations for Service

SPECIAL TOOLS

The following tools are necessary for servicing the

genset:Torque wrench: 0-75 lbs-ft (0-100 N-m)

Tachometer

Digital multi-meter: AC and DC Voltage, Ohms

Load test panel and leads

SAFETY

Hazards and Their Sources

There are hazards in servicing gensets. Study Safe-

ty Precautionsand become familiar with the haz-ards listed in Table 4-1. Note the following safe-guards and ways of avoiding hazards:

Use personal protection:Wear appropriateprotective safety equipment, such as safetyshoes and safety glasses.

Do not wear rings or jewelry and do not wearloose or damp clothing that might get caught inequipment or conduct electricity.

Reduce the hazard:A safe, orderly workshoparea and well-maintained equipment reduce

the hazard potential. Keep guards and shieldsin place on machinery and maintain equipmentin good working condition. Store flammable liq-uids in approved containers; away from fire,flame, spark, pilot light, switches, arc-produc-ing equipment and other ignition sources. Keepthe workshop clean and well-lighted and pro-vide adequate ventilation.

Develop safe work habits: Unsafe actionscause accidents with tools and machines. Befamiliar with the equipment and know how touse it safely. Use the correct tool for the job andcheck its condition before starting. Comply withthe warnings in this manual and take specialprecautions when working around electricalequipment. Do not work alone if possible andtake no risks.

Be prepared for an accident:Keep fire extin-guishers and safety equipment nearby. Agen-cies such as the Red Cross and public safety

departments offer courses in first aid, CPR andfire control. Take advantage of this informationto be ready to respond to an accident. Learn tobe safety-conscious and make safety proce-dures part of the work routine.

TABLE 4-1. HAZARDS AND THEIR SOURCES

Fire andExplosion

Leaking or spilled fuel Hydrogen gas from battery Oily rags improperly stored Flammable liquids improperly

stored

Burns

Hot exhaust pipes Hot engine and generator sur-

faces Electrical shorts

PoisonousGas

Operating genset where ex-haust gases can accumulate

ElectricalShock (AC)

Improper generator connec-tions

Faulty wiring Working in damp conditions Jewelry touching electrical

componentsRotating

Machinery Fan guards not in place

SlipperySurfaces

Leaking or spilled oil

HeavyObjects

Removing genset from vehicle Removing heavy components

Testing the Genset Inside a Building

Make sure there is ample fresh air when operatingthe genset inside a building to prevent carbon mon-oxide asphyxiation.

WARNING EXHAUST GAS IS DEADLY! Engineexhaust must be vented outside if the genset isoperated inside a building.




26/824-2

REMOVING / INSTALLING GENSET

See Section12. Troubleshootingto determine theprobable cause of the problem before removing thegenset for service. The genset is normally mountedin a special compartment on the floor of the vehicleor on a supporting frame. Contact the vehiclemanufacturer or installer if the best way to removethe genset is not obvious.

Disconnections

1. Disconnect the negative (-) battery cable fromthe battery and then disconnect the batterycables from the genset.

WARNING Sparks and high current couldcause fire and other damage to the battery,battery cables and vehicle if the loose endsof cables connected to the battery touch.Always disconnect the negative () batterycable from the battery before disconnectingthe battery cables from the genset.

2. Disconnect the remote control wiring harnessconnector at the genset.

3. Disconnect the AC output leads at the gensetterminals.

4. Disconnect the exhaust tailpipe from the muf-fler flange.

5. Disconnect the supply and return fuel lines fromthe genset.

WARNING Diesel fuel is combustible andcan cause severe personal injury or death.Do not smoke if you are near fuel tanks orfuel-burning equipment or are in an areasharing ventilation with such equipment.Keep flames, sparks, pilot lights, electricalarcs and arc-producing equipment and allother sources of ignition well away.

Removal from Vehicle

Make sure that the genset is firmly supported beforeloosening any mounting bolts. There are four bolt

holes in the skid-base for securing the genset to thefloor or supporting frame. The two lifting eyes are

accessible through the access opening in the toppanel of the genset. Lift the genset with both liftingeyes when using a hoist.

WARNING Gensets are heavy and can causesevere personal injury if dropped during remov-

al. Use adequate lifting devices. Keep handsand feet clear while lifting.

Installation in Vehicle

Generally, installation is the reverse of removal anddisconnection. Before installing the genset, repairany damage to and seal all hoes in the vapor-tight,fire-resistive barrier between the genset and coachinterior. Make sure all mounting screws, and brack-ets are secure and that all battery, AC output, con-

trol, exhaust and fuel connections are proper and ingood repair. Perform the service checklist beforeplacing the genset in service (Section13. Service

Checklist).

Use four Grade 5 screws (3/8-16 UNC) to securethe genset to the floor or frame. The screws mustprotrude at least 1/2 inch (10 mm) but not more than

1 inch (25 mm) into the base, as measured from thebottom surface of the base. Torque the screws to35 lb-ft (41 N-m).




27/824-3

TEST STAND

When testing and servicing the genset on a work-bench or test stand make sure the openings in theskid-base shown in Figure 4-1 (shaded areas) arefree and clear. Also, make sure there is ample freshair when operating the genset.

WARNING EXHAUST GAS IS DEADLY! Engineexhaust must be vented outside if the genset isoperated inside a building.

CAUTION Restricting the air inlet and outletopenings could lead to damage to the gensetdue to overheating.

FIGURE 4-1. AIR INLET AND OUTLET OPENINGS IN BOTTOM (SHADED AREAS)




28/824-4

DISASSEMBLING / REASSEMBLINGHOUSING

Disassembling Housing

WARNING Do not operate the genset withoutthe housing panels secured in place. The panelsguard against rotating parts and bare live elec-trical parts that can cause severe personal inju-ry or death. The housing is also required forproper genset cooling.

See Figure 4-2. The housing consists of removablepanels. The front and top panels include removableservice doors secured by latches or screws.

Remove all the screws around the perimeter of eachpanel and pull the panel away. Note the sets of twoand of three screw holes in the top panel which arecircled. These are for the screws that secure the the

air cleaner housing and the coolant recovery tank,respectively. Remove these screws before liftingthe top panel away.

CAUTION The panel screws are all the samelength. Do not substitute longer screws tomount the air cleaner housing or recovery tank.Longer screws can cause damage by bottomingbefore tight.

Because of overlapping flanges, the top panel mustbe removed to remove the side panels and put backlast.

To remove the end panel on the generator end of thegenset:

1. Cut the wire-tie that secures the wiring har-nesses to the panel.

2. Remove the two output terminal block mount-ing screws to free the output cables from thepanelpreferable to loosening the terminalscrews.

3. Loosen the screws that secure the circuitbreakers to the operators console and pull thecircuit breakers and attached wiring away.

4. Disconnect the leads at the terminals on thecontrol switch and hour meter.

5. Remove the mounting screws to free auxiliaryrelays K1, K2 and K3 (p. 11-6)

6. Prior to Spec C, disconnect Controller connec-tors P1/J1 and P2/J2 (p. 11-2).

7. Disconnect the two air intake hoses from the airintake resonator box.

8. Remove all attachment screws and pull thepanel away.

Reassembling Housing

Reassembly is the reverse of disassembly. To makesure that all of the panel screw holes will line up, waitto tighten the screws until all of the panels andscrews are in place.

When reassembling, torque the panel screws to8 lb-ft (11 N-m).

Note: When securing the side service door frame to

the panel on its right, the frame and panel shouldtouch metal-to-metal. Pull the sound absorbing in-sulation back a little, if necessary, so that it is notpinched between the panel and frame. That way theinsulation covers the slots in the door frame whichwould otherwise let some noise out.




29/82

45

SCREW HOLES FOR MOUNTINGCOOLANT RECOVERY TANK AND

AIR CLEANER HOUSING

PRIOR TOSPEC C

BEGINNINGSPEC CBRUSH

BLOCKACCESS

COOLANT& FUSEACCESS

FIGURE 4-2. HOUSING PANELS


30/824-6





31/825-1

5. Fuel System

WARNING Accidental or remote starting cancause severe personal injury or death. Beforeremoving a housing panel or access door, dis-

connect the negative () cable at the battery toprevent the engine from starting.

Figure 5-1 shows the components of the fuel systemup to the connections at the engine.

WARNING Diesel fuel is combustible and cancause severe personal injury or death. Do notsmoke near fuel tanks or fuel-burning equip-ment or are in an area sharing ventilation withsuch equipment. Keep flames, sparks, pilotflames, electrical arcs and switches and other

sources of ignition well away. Keep a type ABCfire extinguisher handy.

CAUTION Always wipe dirt off fuel fittings be-fore disconnecting them to keep dirt from enter-ing the fuel system.

CAUTION Dips in the fuel lines can trap airand cause difficult priming. Secure the two fuelhoses as shown to prevent traps.

FUEL INJECTION SYSTEM

See Engine Workshop Manual 981-0525 regardingfuel injection system service.

FUEL FILTER

The fuel filter is mounted on a bracket on the side ofthe base and is accessible through the front access

door. See Page 3-7 regarding fuel filter replace-ment.

FUEL PUMP

Fuel Flow Test

1. Disconnect the fuel return hose from the line tothe supply tank and point the end into a quart(1 liter) or larger container that has volumegraduations.

2. Prime the genset by pushing the Start/Stopswitch to STOP and holding it there for theduration of the test. Flow should not be lessthan 200 ml (0.4 pints) per minute.

3. If flow is less than specified, replace the fuel fil-ter. If that does not help, look for other restric-tions in the fuel system. Last, replace the fuelpump. The pump is not serviceable.

Removal and Installation

The fuel pump mounting screws are on the frontside of the base and the fuel pump is removeableand replaceable through the opening in the bottomof the base.

Connect the fittings on both ends of the fuel line byhand before tightening either. Use flare-nutwrenches to tighten the fittings so as not to roundthe corners on the nuts and two wrenches at eachfitting so as not to stress the pump or filter. Tighteneach fitting one flat past seating.




32/825-2

FUELRETURN

LINE

TO FUEL INJECTIONPUMPS

FUELFILTER

FUELPUMPTIE WRAP BOTH FUEL HOSES TO

THE GENERATOR FAN GUARD ATTHIS NOTCH SO THAT THERE

ARE NO DIPS THAT CAN TRAP AIR

FIGURE 5-1. FUEL SYSTEM TO ENGINE




33/826-1

6. Air Intake System



Remove the top and back housing panels for ac-

cess (p. 4-4). To reassemble the air intake system,refer to Figure 6-1 for models Beginning Spec Corto Figure 6-2 for models Prior to Spec C.

CAUTION Do not cut the engine intake airtubes to make them fit better. Their lengthsare critical for proper noise attenuation.

AIR CLEANER HOUSINGSECUREDTO HOUSING TOP PANEL BY THE 2

SCREWS SHOWNAIR INTAKE TUBEENGINE

AND GENERATOR

ENGINE INTAKEAIR RESONATOR

GENERATOR INTAKECOVER


SCREWS SHOWN

FIGURE 6-1. AIR INTAKE COMPONENTS (BEGINNING SPEC C)




34/826-2

USE 2 TIE-WRAPS TO TIEAIR TUBE TO BOTTOM OFBOTH RADIATOR HOSES

TO KEEP TUBE FROMBLOCKING RADIATOR

GENERATORCOOLING AIR

TUBE


SCREWS SHOWN

ENGINE INTAKEAIR RESONATOR

FIGURE 6-2. AIR INTAKE COMPONENTS (PRIOR TO SPEC C)




35/827-1

7. Exhaust System



The muffler is bolted directly to the outlet flange ofthe engine exhaust manifold and a flexible, corru-gated stainless steel tube is bolted to the muffleroutlet flange (Figure 7-1). The flange on the otherend of the flexible tube is bolted to the base assem-bly.

Flanged tailpipe adaptors are available for tailpipeconnections out the end, back or bottom of the gen-

set. See the Installation Manual for important safetywarnings and instructions regarding the routing andtermination of the tailpipe (not supplied by Onan).

Always use new flange gaskets when connectingexhaust system components.

See Page 3-6 regarding spark arrestor cleaning.

To remove the muffler:

1. Disconnect the negative (-) battery cable fromthe batteryto prevent the genset from starting

and remove the top and back housing panels(p. 4-4).

2. Disconnect the exhaust tail pipe and removethe flanged tail pipe adaptor.

3. Remove the flange screws on both ends of theflexible tube and withdraw the tube out the endof the genset.

CAUTION The flexible tube is fragile. Takecare not to bend or twist it.

4. Remove the screws from the 2 muffler supportbrackets and the muffler manifold flange andwithdraw the muffler.

Installation of the muffler is the reverse of removal.Use new flange gaskets for the tail pipe adaptor,flexible tube and muffler. Tighten all screws and nutsaccording to specifications (p. 15-1).

WARNING Exhaust gas is deadly. The exhaustsystem must not leak. Liability for injury, death,damage and warranty expense due to the use ofan unapproved muffler or due to modificationsbecomes the responsibility of the person instal-ling the unapproved muffler or performing themodifications. Use Onan approved exhaustsystem parts.




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FIGURE 7-1. MUFFLER ASSEMBLY




37/828-1

8. Engine Cooling System



The genset has a liquid-cooled engine with integral,belt-driven coolant pump (Figure 8-2). The radiatoris mounted horizontally in the base of the genset.The system drain plug is on the radiator end tank.The coolant recovery tank is mounted on the under-side of the top housing panel.

Beginning Spec C, refer to Figure 8-1 to reassem-ble the cooling system components.

Prior to Spec C, refer to Figure 8-2 to reassemblethe cooling system components.

A centrifugal blower (fan) is bolted on a spacer to thetop belt pulley on the engine. It pulls cooling air upthrough the radiator and across all of the compo-nents inside the housing. The warm air is dis-charged out the bottom opening in the right end ofthe base.

See Page 3-8 regarding periodic cooling systemmaintenance.

See Page 9-3 regarding the coolant temperaturesender.

THERMOSTAT AND PUMP

See Engine Workshop Manual 981-0525 for coolantthermostat and pump service. The fan must comeoff to remove the pump.

RADIATOR

To remove the radiator:1. Disconnect the negative (-) battery cable from

the batteryto prevent the genset from starting.

2. Let the genset cool down and then drain thecooling system (p. 3-8).

WARNING Hot coolant spray can cause se-vere burns. Let the engine cool before re-leasing the pressure cap or removing thedrain cap.

3. Remove the radiator access cover on the backof the base.

4. Disconnect the two radiator hoses and with-draw the radiator out the side opening in thebase.

Installation of the radiator is the reverse of removal.Replace the foam sealing strips around the openingin the base if they are damaged so that air is drawnthrough the radiator and not around it. Tighten allscrews according to specifications (p. 15-1).

FAN (BLOWER)

To remove the fan:

1. Remove the top and end housing panels(p. 4-4).

2. Remove the fan scroll.

3. Remove the four fan hub bolts and withdraw thefan and spacer.

CAUTION The fan (blower wheel) is frag-ile. Do not brace against it when looseningor tightening the hub bolts.

Installation is the reverse of removal. To prevent re-circulation of air, replace the foam sealing stripsaround the opening of the inner bulkhead (baffle) ifthey are damaged. Tighten all screws according tospecifications (p. 15-1).

FAN BELT

Belt Tension

Remove the top genset housing panel (p. 4-4). Ad-just tension so that deflection is 8-10 mm(0.3-0.4 inch) midway between the alternator andpump pulleys when a force of 10 kg (22 pounds) isapplied.

Belt Replacement

Remove the fan and then install the new belt and ad-just its tension.




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PRESSURECAP

COOLANTRECOVERY

TANK

INNERBULKHEAD(BAFFLE)

FAN BACKPLATE

FANFAN

SCROLL

VENT LINE(Must be routed through clips on top of engine valve coverto keep tube from sagging, creating air traps that can pre-

vent complete system filling. Also, a replacement hosemust be 491/2 inches [1257 mm] long.)

FAN BACKPLATEMOUNTING BRACKETS

(EACH SIDE)

RADIATORACCESSCOVER

RADIATORHOSES

RADIATOR

FIGURE 8-1. ENGINE COOLING SYSTEM (BEGINNING SPEC C)


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PRESSURECAP

COOLANTRECOVERY

TANK

RADIATOR

INNERBULKHEAD(BAFFLE)

FAN BACKPLATE

FANFAN

SCROLL

VENT LINE(Must be routed through clips on top of engine valve cover[not shown] to keep tube from sagging, creating air trapsthat can prevent complete system filling. Also, a replace-

ment hose must be 491/2 inches [1257 mm] long.)

FAN BACKPLATEMOUNTING BRACKETS

(EACH SIDE)

RADIATORHOSES

RADIATORACCESSCOVER

FIGURE 8-2. ENGINE COOLING SYSTEM (PRIOR TO SPEC C)


40/828-4





41/829-1

9. Engine and Accessories



ENGINE

See Engine Workshop Manual 981-0525 for servic-ing the engine proper: adjusting valve clearance(lash), servicing the fuel injection system, replacingthe glow plugs, cleaning the crankcase breather as-sembly, replacing the coolant thermostat and pumpand overhauling the engine.

Removal

The engine-generator assembly and wiring har-nesses should be removed as an assembly from thegenset if it is necessary to remove either the engine(Figure 9-1) or the generator (Figure 10-1 or 10-2).To do so:

1. Remove all of the housing panels except the in-ner bulkhead (p. 4-4), leaving the wiring har-nesses attached to the engine-generator as-sembly.

2. Drain the cooling system, disconnect the radia-

tor and vent hoses from the engine and removethe blower (fan) assembly (p. 8-1).

3. Remove the radiator (p. 8-1) for access to thebolt head of the generator isolation mount.

4. Disconnect the generator cooling air tube fromthe generator (p. 6-1 or 6-2).

5. Disconnect the battery cables and basegrounding strap from the engine (on starterside).

6. Disconnect the wiring harness lead to the fuelpump.

7. Disconnect the supply and return fuel hoses atthe engine (p. 5-2).

8. Disconnect the flexible connector from the muf-fler outlet flange (p. 7-2).

9. Attach a hoist of sufficient capacity to the liftingeye, take up the slack and remove the centerbolts of the three isolation mounts. Lift the en-gine-generator assembly away.

Installation

Installation is the reverse of removal. Make sure theair seal ring is in place around the oil drain hole in thebase to keep air from bypassing the radiator. (Theengine-generator compartment is under a partial

vacuum.) Tighten all screws to specifications(p. 15-1).




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92

FLYWHEEL

HOUSING

AIR SEALAROUND OILDRAIN PLUG

LOW OILPRESSURE

CUTOFFSWITCH

GOVERNORACTUATOR

STARTERMOTOR ANDSOLENOID

FLYWHEEL

VENT HOSEFITTING

COOLANTTEMPERATURE

SENDER

BATTERYCHARGING

ALTERNATOR

LIFTING EYE

FLYWHEEL

HOUSING

FIGURE 9-1. ENGINE AND ACCESSORIES


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WARNING Accidental or remote starting cancause severe personal injury or death. Beforeremoving a housing panel or access door, dis-connect the negative () cable at the battery toprevent the engine from starting.

ENGINE SENSORS

The engine is equipped with a coolant temperaturesender and low oil pressure cutout switch (Fig-ure 9-1). The associated fault codes (Sec-tion12. Troubleshooting) are as follows:

No. 1 -Engine Over Temperature

No. 2 -Low Oil Pressure

No. 23 - Faulty Low Oil Pressure Cutout Switch

No. 24 - Faulty Engine Temperature Sender

Coolant Temperature Sender

The sender is accessible through the front accessopening. Replace the sender if resistance is notapproximately 1300 ohms in ice water, 700 ohms atroom temperature or 57 ohms in boiling water. Usethread sealant and engage at least two threadswhen reassembling.

Oil Pressure Switch

The switch is accessible through the top accessopening with the manifold air hose disconnected

and moved out of the way. Replace the switch if it isnot closed (ground continuity at the terminal) whenthe engine is not running or if the switch does notopen when oil pressure rises to 14 psi (96 kPa).

BATTERY CHARGING ALTERNATOR

The battery charging alternator (Figure 9-1) is re-

moveable after the fan assembly and backplate areremoved (p. 8-2 or 8-3). Adjust fan belt tension andtighten the mounting bolts according specifications(p. 15-1) when reassembling.

STARTER MOTOR

The starter motor (Figure 9-1) is removeablethrough the top access opening. Tighten the mount-ing bolts according specifications (p. 15-1) when re-assembling.

GLOW PLUGSRefer to engine Workshop Manual 981-0525 whenreplacing the glow plugs, which are accessiblethrough the top access opening.

Note: If a glow plug does not come out after un-screwing it, or the end has broken off, it will benecessary to remove the engine head. Glowplugs can swell if preheat voltage is greater than14 volts, such as when a battery booster is usedfor starting.




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GOVERNOR ACTUATOR

The governor actuator (Figure 9-1) is removeablethrough the front access opening. Disconnect theactuator and unscrew it from the engine block.When reassembling, use Loctite 587 ultra-bluesealant or equivalent on the seat. Do not apply thesealant to the threads. Replace the actuator if:

Electrical resistance across its terminals is not2.8 to 2.9 ohms.

The plunger does not pull in when B+ (12 VDC)is applied across its leads.

The plunger does not move in and out smoothlywhen pushed in by hand.

HIGH-IDLE SPEED

Reset high-idle speed if the stop screw seal hasbeen broken or internal governor parts have beenreplaced or are worn. To reset high-idle speed:

1. Remove the top housing panel (p. 4-4) for ac-cess to the stop screw (Figure 9-2).

2. Remove the governor actuator to allow opera-tion at full fuel rack, but leave it connected to

keep Fault No. 19 from preventing Start. Plugthe opening to keep oil from splashing out.

3. Disconnect the fuel pump and power it directlywith a 12 volt battery to keep the engine run-ning when Fault No. 12 or 14 occurs.

4. Disconnect all loads from the genset to protectthem from overfrequencyand start the genset.Adjust the stop screw to obtain 67.3-68.3 Hertz(2019-2049 rpm). TO STOP THE ENGINE,disconnect the fuel pump from the battery.

CAUTION With the housing top off the en-gine could overheat if run longer than 5 min-utes or so. Let is cool down, if necessary,before continuing the test.

5. Check speed with the top panel and accesscover on. Frequency should rise slightly to68-69 Hertz (2040-2070 rpm). Repeat if neces-sary and seal the adjusting threads with paint.

6. Re-install the actuator, reconnect the fuel pumpand secure the housing top and access cover.

HIGH-IDLESPEED STOP

SCREW HIGH-IDLESPEED LEVER

LOCKNUT

FIGURE 9-2. HIGH-IDLE SPEED STOP SCREW




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10. Generator



GENERATOR WINDING TESTS

Testing Winding Insulation Resistance

Testing for Winding-to-Winding and Winding-to-Ground Shorts:A digital ohmmeter can be used(highest scale) as a preliminary check for agrounded Stator, Quadrature or Field Winding or fora short between Stator (Main) and Quadrature

windings. The meter should indicate infinite resist-ance.

A 500 VDC megger is recommended for findingwinding-to-winding or winding-to-ground shorts.Resistance between windings or to ground shouldbe not be less than 1 megohm.

Testing Stator Windings with a Megger:A 500VDC megger is recommended for testing StatorWinding insulation resistance. Disconnect T2 andT3 from the grounding screw on the engine mount-

ing bracket (p. A-3) to isolate the windings fromground, and separate the two parts of generatorconnector P3/J3 to isolate the control board fromthe DC test voltage. Apply one side of the DC testvoltage to both windings (connect to either end) andthe other side to a good generator ground (statorlaminations) for 10 minutes and record resistancevalues at one minute and at 10 minutes.

A resistance value of at least 5 megohms should beobtained for a new stator with dry windings. The po-larization index (the ratio of the resistance reading

at 10 minutes to the reading at one minute) shouldalso be at least 2. For a genset that has been in ser-vice, the resistance value should not be less than1 megohm, nor the polarization index less than 2.

If the readings are low, or the genset has been instorage for a long time in a high-humidity environ-ment, the test should be repeated after the windingshave been dried. The most effective way of dryingthe stator windings, if the genset is operable, is torun it under full load for at least one hour.

Testing Winding Resistance

Use a Digital Ohmmeter to check for open or

shorted Main (Stator), Quadrature or Field Wind-ings. Use a Wheatstone Bridgehaving a precisionof at least 0.001 ohm to measure Stator Winding re-sistance.

Replace a rotor or stator that has windingresistances outside Table 10-1 tolerances.

Stator Windings:Check Stator Winding resistanceacross the AC output terminal block: TB2-1TB2-3and TB2-2TB2-3. Make sure circuit breakerCB1/CB2 is ON.

If resistance is within Table 10-1 tolerances, thewhole AC output circuit is probably sound.

If resistance is high, check resistance directlyacross the winding leads, which are connected atCB1/CB2 and at the grounding screw on the enginemounting bracket (p. A-3). Service as necessary bytightening connections or servicing the generator,AC harness (p. A-3) or circuit breakers (p. 11-6).

Field and Quadrature Windings: Separate the

two parts of generator connector P3/J3 for accessto the field windings (P3-7P3-8) and quadraturewindings (P3-3P3-6). Resistance must withinTable 10-1 tolerances. If field resistance is high, firstservice the brushes and slip rings (p. 10-4) and re-peat the test. Then, if necessary, service the rotor.

TABLE 10-1. WINDING RESISTANCES

RESISTANCE (OHMS) @ 705 F (215 C)

WINDING

BeginningSpec C

Prior toSpec C

HDCAA

HDCAC

HDCAB

HDCAD

All Models

T1-T2, T3-T4 0.197-0.241 0.178-0.218 0.197-0.241

Q1-Q60(P3-3 to P3-6)

1.99-2.42 1.89-2.31 1.99-2.42

Rotor(P3-7 to P3-8)

19.4 22.5 19.4

Note: Even though winding resistance may be within thetolerances of this Table, replace the Rotor or Stator ifwinding-to-winding or winding-to-ground resistance (wind-ing insulation resistance) is less than 1 megohm. (Anohmmeter must indicate an opencircuitor infinite resistancebetween windings or between any winding and ground.)




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2

BRUSH BLOCK ASSEMBLY

ADAPTORCASTING

FAN

DRIVE DISC(assemble with

chamferededge out)

END BELL

THROUGH BOLTS (4)(thread the ends with

shorter lengths of threadinto the adaptor)

ROTORBEARING

GENERATORLEAD EXIT ANDBRUSH BLOCK

ACCESS

STATORASSEMBLY

SLIP RINGS

ROTORASSEMBLY

GENERATORINTAKECOVER

O-RING

CONTROL BOARD

GUARDSCREEN

FIGURE 10-1. GENERATOR (BEGINNING SPEC C)


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3

BRUSH BLOCK ASSEMBLY

AIR INLET DUCTADAPTOR ASSEMBLY

ADAPTORCASTING

FAN

DRIVE DISC(assemble with

chamfered edge out)

END BELL

STATORASSEMBLY

SLIP RINGS

THROUGH BOLTS (4)(thread the ends with

shorter lengths of threadinto the adaptor)

ROTORASSEMBLY

GUARDSCREEN

ROTORBEARING

O-RING

GENERATORLEAD EXIT

FIGURE 10-2. GENERATOR (PRIOR TO SPEC C)


48/8210-4

GENERATOR SERVICE


Brushes and Slip RingsAccess Beginning Spec C: Remove the brushblock access cover (p. 4-4) for access to the brushblock assembly and slip rings.

Access Prior to Spec C:Remove the housing endpanel (p. 4-4) and the generator air duct adaptor as-sembly (Page 12-1) for access to the brush blockassembly and slip rings.

Checking for Wear:Check brush wear by markingoff a piece of wire at 1 inch (25 mm) and inserting itinto each of the two holes in the top of the brush

block from which the pig tails exit. Replace the brushif the wire can be inserted more than 1 inch (25 mm).(Make sure the wire rests on top of the brush and noton part of the spring.)

Cleaning Up Slip Rings: If the slip rings aregrooved or pitted, try cleaning them up with a com-mutator stone while cranking the engine. (Connectthe starter motor directly to a battery and the startersolenoid to a remote start switch.) The rotor willhave to be removed if the slip ring assembly has tobe replaced.

Replacing Brush Block:When replacing the brush

block assembly, center the brushes on the slip ringsbefore tightening the two mounting screws. Makesure to reconnect the lead marked F1 to the out-board brush and the lead marked F2 to the inboardbrush.

BRUSH LEADTERMINAL

FIGURE 10-3. BRUSH BLOCK ASSEMBLY




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Removing the Generator

Remove the engine-generator assembly as an as-sembly from the genset (p. 9-1) and then removethe generator from the engine, as follows:

1. Remove the air inlet assembly (Figure 10-1or 10-2).

2. Disconnect the generator leads attached to thegrounding screw on the engine mountingbracket (Page A-3) and separate the two partsof generator connector P3/J3.

3. Remove the brush block assembly or lift thebrushes and insert a wire to keep the brushesup and out of the way while disassembling andreassembling the generator.

4. Loosen the four through bolt nuts and removethe end bell and stator assemblies.

5. Remove the adaptor casting from the flywheelhousing and then the rotor from the flywheel.

Installing the Generator

Installation is the reverse of removal. Tighten allnuts and bolts according to specifications (p. 15-1)

and note the following:

1. Make sure the chamfered edge of the drive discfaces the flywheel.

2. Make sure the ends of the through bolts with theshorter lengths of thread are threaded into theadaptor casting.

3. Make sure the O-ring is in place in the bearing

bore of the end bell. Grease the bore lightly tomake assembly easier.

4. Before securing the the air inlet adaptor assem-bly, make sure the brush block assembly is inplace (Brushes and Slip Rings) and that thewire holding up the brushes has been removed.

Replacing the Rotor Bearing

Use a gear puller if it is necessary to remove the ro-tor bearing. If the slip ring assembly is being re-placed, install the new assembly before pressing onthe bearing. Press a new rotor bearing on flush withthe end of the rotor. Apply Loctite #680 adhesive tothe shaft and Loctite #747 activator to the bearingmating surface.

Replacing the Slip Ring Assembly

Remove the rotor bearing and unsolder the two fieldleads if it is necessary to remove the slip ring as-sembly. Press a new slip ring assembly on makingsure the key is in place and soldered the field leads

to the slip ring assembly.




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ADJUSTING VOLTAGE

Beginning Spec C, voltage is adjustable by meansof the control switch. Rapidly pressing the switch toSTART 6 times during the first minute after startupputs the genset controller into voltage set mode.The status indicator lamp blinks once every secondto confirm voltage set mode. The controller will re-

sume normal operating mode 20 seconds after thelast adjustment.

WARNING HAZARDOUS VOLTAGE! Touchinguninsulated live parts inside the genset or con-nected equipment can result in severe personalinjury or death. For your protection, stand on adry wooden platform or rubber insulating mat,make sure your clothing and shoes are dry, re-move jewelry from your hands and use toolswith insulated handles.

To adjust voltage:1. Disconnect all generator loads and connect ac-

curate meters to measure AC voltage and fre-quency.

2. Start the genset and let voltage and frequencystabilize for 5 to 10 seconds.

3. Rapidly press the control switch to START6 times within 10 seconds.

4. To adjust voltage up, press the control switchto START and release quickly. Each time the

switch is released, voltage will rise approxi-mately 0.6 volt.

5. To adjust voltage down, press the controlswitch to START and release in 1 second.Each time the switch is released, voltage willdrop approximately 0.6 volt.

6. Normal operation will resume in 20 seconds af-ter the last adjustment. The last adjustment willbe retained by the controller.

Note: If a fault shutdown occurs or the controlswitch is pressed to STOP during voltage setmode, voltage adjustments will not be stored incontroller memory.




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11. Control



CONTROL BOARD (CONTROLLER)

The Control Board is an integrated microprocessor-based engine and generator control that provides allthe control, monitoring and diagnostic functions re-quired to operate the genset.

Control Board (Beginning Spec C)

Location and Mounting: Refer to Figure 11-1 forcontrol board location and mounting and toPages A-1 and A-2 for the applicable control sche-matic and wiring harness. The control board is ac-

cessible for replacement through the front or top ac-cess openings.

Connector:A single connector (P1/J1) is used forall connections between the control board and har-ness. When separating the connector, use a smallflat-bladed screwdriver to lever out the catch.

CAUTION Makeshift meter test probes usedfor testing Control Board connections duringtroubleshooting can damage pin sockets byspreading or dislodging the contact wiper arms,resulting in an open or intermittent electricalconnection. Use a mating pin (PN 3231605) or atest probe that is 0.045 inches in diameter. Re-place damaged pin sockets (PN 323161401).Make sure the pin sockets are fully seated andcant be pulled out.

CONTROL

BOARD

CONNECTOR

J1

GENERATOR

INTAKE COVER

FIGURE. 11-1 CONTROL BOARD (BEGINNING SPEC C)




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Control Board (Prior to Spec C)

Refer to Figure 11-2 for control board location andmounting and to Pages A-4 and A-5 for the applica-ble control schematic and wiring harness.The con-trol board is mounted inside the engine air intakeresonator with three screws.

Connectors:Two connectors, P1/J1, which is grayand mounted outboard of the other connector, andP2/J2, which is black and mounted inboard, areused for all connections between the control boardand harness. When separating the connectors, usea small flat-bladed screwdriver to lever out thecatch.

CAUTION Makeshift meter test probes usedfor testing Control Board connections duringtroubleshooting can damage pin sockets byspreading or dislodging the contact wiper arms,

resulting in an open or intermittent electricalconnection. Use a mating pin (PN 3231605) or atest probe that is 0.045 inches in diameter. Re-place damaged pin sockets (PN 323161401).Make sure the pin sockets are fully seated andcant be pulled out.


Removing the Control Board:

1. Remove the top and back housing panels andtilt out the end panel (p. 4-4).

2. Disconnect the two connectors from the controlboard. Use a small flat-bladed screwdriver tolever out the catch on the connectors.

3. Remove the two air tubes from the resonatorassembly and the six nuts that secure the reso-nator to the housing panel and pu

Manual de Operador Onan 10HDCAC

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